Zeolite Seed Crystal Adhesion on Vertical Supports

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Solution Overview

Problem

The formation of a uniform zeolite membrane is hindered by weak adhesion of seed crystals to the support, particularly on vertical planes, requiring specialized supports and complex production processes, as seen with AlPO-based zeolites.

Innovation Solution

The development of seed crystals with a specific surface area between 10 m2/g and 150 m2/g and a crystal component strength 1 to 30 times that of the amorphous component, attached to a porous support like alumina or mullite, using hydrothermal synthesis and controlled pulverization methods, enhances adhesion and uniformity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If seed crystals of AlPO-based zeolite are used, then the zeolite membrane can be formed, but the adhesion of seed crystals to the support is weak, causing non-uniform attachment on vertical planes

Engineering Contradiction:

Improveadhesion of seed crystalsVSAvoiduniformity of seed crystal attachment

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent changes the physical parameters of the seed crystals by controlling their specific surface area (10-150 m²/g) and crystal component strength (1-30 times that of amorphous component). These parameter adjustments improve adhesion to the support while maintaining uniform attachment on vertical planes, resolving the contradiction between reliability and manufacturing precision.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a special support with alkali metal or alkali earth metal arranged on its surface is used to improve seed crystal adhesion, then the adhesion is enhanced, but the production process becomes complicated

Engineering Contradiction:

Improveadhesion of seed crystalsVSAvoidsupport structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Instead of modifying the support structure, the patent changes the parameters of the seed crystals themselves (specific surface area and crystal component strength). This approach enhances adhesion without requiring complex support structures with arranged metals, thereby resolving the contradiction between reliability and device complexity.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the specific surface area of seed crystals is increased to improve adhesion, then the adherence to support improves, but the crystal structure may become less stable

Engineering Contradiction:

Improveadherence of seed crystalsVSAvoidcrystal structure stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent optimizes the specific surface area within a specific range (10-150 m²/g) and controls the crystal component strength (1-30 times that of amorphous component). This balanced parameter adjustment ensures both good adhesion and structural stability, resolving the contradiction between reliability and composition stability.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach improves the adherence of seed crystals to the support, enabling the formation of a dense and uniform zeolite membrane, even on vertical planes, and maintains suitable growth for effective gas separation applications.

Implementation Method 1

hydrothermal synthesis or the like is performed in a state where the support with the seed crystals attached thereto is immersed in a precursor solution. This causes the zeolite to grow from the seed crystals as a nucleus, and the zeolite membrane is thereby formed on the support.

Methodology Applied

Scientific EffectHydrothermal synthesis:

Implementation Method 2

The strength obtained from a crystal component at a diffraction angle 2θ indicating a maximum peak in a range of diffraction angle 2θ from 12° to 25° in an X-ray diffraction pattern obtained by emitting X-ray to the seed crystals

Methodology Applied

Scientific EffectX-ray diffraction: X-Ray

Data Source

PatentUS11492264B2Seed crystals, method of producing seed crystals, method of producing seed crystals attachment support, and method of producing zeolite membrane complex

Publication Date: 2022.11.08 NGK INSULATORS LTD

AI summary

Seed crystals are crystals of zeolite to be attached onto a support in production of a zeolite membrane complex including the support and a zeolite membrane formed on the support. The specific surface area of the seed crystals is not smaller than 10 m2/g and not larger than 150 m2/g. The strength obtained from a crystal component at a diffraction angle 2θ indicating a maximum peak in a range of diffraction angle 2θ from 12° to 25° in an X-ray diffraction pattern obtained by emitting X-ray to the seed crystals is not less than once and not more than 30 times that obtained from an amorphous component. It is thereby possible to improve adherence of the seed crystals to the support.